Patent application title: Material separator systems

Abstract:

A vehicle for separating a mixed debris stream is disclosed. The vehicle
may include an elongate vehicle frame; a separating structure mounted on
the vehicle frame and configured to contact the mixed debris stream with
a fluid stream to separate the mixed debris stream into at least a first
debris stream and a second debris stream; a first conveyor; a second
conveyor; and a fluid collection structure configured to receive fluid
from at least one of the separating structure, the first conveyor, and
the second conveyor, the fluid collection structure including an upper
tank, a lower tank, and one or more conduits fluidly connecting the upper
and lower tanks, wherein the one or more conduits are free from a valve
configured to regulate flow from the upper tank toward the lower tank.

Claims:

1. A vehicle for separating a mixed debris stream, comprising:an elongate
vehicle frame;a separating structure mounted on the vehicle frame and
configured to contact the mixed debris stream with a fluid stream to
separate the mixed debris stream into at least a first debris stream and
a second debris stream, wherein the second debris stream includes at
least some material of a higher density than material from the first
debris stream;a first conveyor having a feed end portion positioned to
receive the first debris stream from the separating structure, and a
discharge end portion spaced from the feed end portion of the first
conveyor;a second conveyor having a feed end portion positioned to
receive the second debris stream from the separating structure, and a
discharge end portion spaced from the feed end portion of the second
conveyor; anda fluid collection structure configured to receive fluid
from at least one of the separating structure, the first conveyor, and
the second conveyor, the fluid collection structure including an upper
tank, a lower tank, and one or more conduits fluidly connecting the upper
and lower tanks, wherein the one or more conduits are free from a valve
configured to regulate flow from the upper tank toward the lower tank.

2. The vehicle of claim 1, wherein the one or more conduits include at
least one weir configured to allow fluid from the upper tank to flow
toward the lower tank when a fluid level in the upper tank is beyond a
predetermined level.

3. The vehicle of claim 2, wherein the fluid collection structure further
includes an internal wall defining the upper and lower tanks, and the at
least one weir is spaced from the internal wall.

4. The vehicle of claim 1, wherein the one or more conduits include at
least one passage extending between the upper tank and the lower tank,
and further comprising at least one flow directing assembly configured to
direct fluid from the upper tank toward the at least one passage.

5. The vehicle of claim 4, wherein the at least one flow directing
assembly includes a bubbler adjacent the at least one passage and
configured to inject fluid into the upper tank.

6. The vehicle of claim 5, wherein the fluid collection structure further
includes an internal wall defining the upper and lower tanks, and wherein
the at least one passage extends through the internal wall between the
upper and lower tanks, and the bubbler is on the bottom adjacent the at
least one passage.

7. The vehicle of claim 1, wherein the separating structure is configured
to contact the mixed debris stream with the fluid stream at a contact
region, the contact region being spaced from the feed end portion of the
first conveyor, and wherein the separating structure is further
configured to selectively direct the fluid stream to move the contact
region among a plurality of locations relative to the feed end portion of
the first conveyor.

8. The vehicle of claim 7, wherein at least one of the first and second
conveyors includes a non-mesh conveyor belt configured to drain at least
some fluid from at least one of the first and second debris streams, and
wherein the non-mesh conveyor belt includes a plurality of holes
configured to drain at least some fluid from at least one of the first
and second debris streams.

9. The vehicle of claim 8, wherein the plurality of holes of the non-mesh
conveyor belt includes plural arrays of holes, and each array of holes
includes plural staggered rows of holes.

10. The vehicle of claim 9, wherein the non-mesh conveyor belt includes
elongate cleats configured to prevent material from at least one of the
first and second debris streams from moving toward the feed end portion
of at least one of the first and second conveyors, and wherein the
elongate cleats are disposed between the plural staggered rows of holes.

11. A vehicle for separating a mixed debris stream, comprising:an elongate
vehicle frame;a separating structure mounted on the vehicle frame and
configured to contact the mixed debris stream with a fluid stream to
separate the mixed debris stream into at least a first debris stream and
a second debris stream, wherein the second debris stream includes at
least some material of a higher density than material from the first
debris stream;a first conveyor having a feed end portion positioned to
receive the first debris stream from the separating structure, and a
discharge end portion spaced from the feed end portion of the first
conveyor;a second conveyor having a feed end portion positioned to
receive the second debris stream from the separating structure, and a
discharge end portion spaced from the feed end portion of the second
conveyor; anda fluid collection structure configured to receive fluid
from at least one of the separating structure, the first conveyor, and
the second conveyor, the fluid collection structure including an internal
wall defining an upper tank and a lower tank, and one or more conduits
fluidly connecting the upper and lower tanks, wherein the one or more
conduits are spaced from the internal wall.

12. The vehicle of claim 11, wherein the one or more conduits include at
least one weir configured to allow fluid from the upper tank to flow
toward the lower tank when a fluid level in the upper tank is beyond a
predetermined level.

13. The vehicle of claim 11, wherein the one or more conduits include at
least one passage extending through the internal wall between the upper
and lower tanks.

14. The vehicle of claim 13, further comprising at least one flow
directing assembly adjacent the at least one passage.

15. The vehicle of claim 14, wherein the at least one flow directing
assembly includes a bubbler configured to inject fluid into the upper
tank.

16. A vehicle for separating a mixed debris stream, comprising:an elongate
vehicle frame;a separating structure mounted on the vehicle frame and
configured to contact the mixed debris stream with a fluid stream to
separate the mixed debris stream into at least a first debris stream and
a second debris stream, wherein the second debris stream includes at
least some material of a higher density than material from the first
debris stream;a first conveyor having a feed end portion positioned to
receive the first debris stream from the separating structure, and a
discharge end portion spaced from the feed end portion of the first
conveyor;a second conveyor having a feed end portion positioned to
receive the second debris stream from the separating structure, and a
discharge end portion spaced from the feed end portion of the second
conveyor; anda fluid collection structure configured to receive fluid
from at least one of the separating structure, the first conveyor, and
the second conveyor, the fluid collection structure including an internal
wall defining an upper tank and a lower tank, and one or more conduits
fluidly connecting the upper and lower tanks, wherein the one or more
conduits are external the upper and lower tanks and are free from a valve
configured to regulate flow between the upper and lower tanks.

17. The vehicle of claim 16, wherein the one or more conduits include at
least one weir configured to allow fluid from the upper tank to flow
toward the lower tank when a fluid level in the upper tank is beyond a
predetermined level.

18. The vehicle of claim 16, wherein the one or more conduits include at
least one passage extending through the internal wall between the upper
and lower tanks.

19. The vehicle of claim 18, further comprising a flow directing assembly
configured to direct fluid from the upper tank toward the at least one
passage.

20. The vehicle of claim 19, wherein the flow directing assembly includes
a bubbler configured to inject fluid into the upper tank.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application is a continuation-in-part of U.S. patent
application Ser. No. 12/151,781, filed May 8, 2008 and entitled "Material
Separator Systems," which is a continuation-in-part of U.S. patent
application Ser. No. 11/985,211, filed Nov. 13, 2007 and entitled
"Material Separator Systems," which is a continuation-in-part of U.S.
patent application Ser. No. 11/600,403, filed Nov. 15, 2006 and entitled
"Material Separator System." The complete disclosures of the above
applications are herein incorporated by reference for all purposes.

BACKGROUND OF THE DISCLOSURE

[0002]Various systems are used for processing dirt and/or debris mixtures,
which may include rocks, concrete pieces, wood pieces, stones, discarded
hardware, and other types of dirt and/or debris. That processing may
include feeding and screening the dirt and/or debris mixtures into
multiple piles. For example, one pile may contain essentially soil, and
other piles may contain material of different sizes with at least some of
those piles having commercial value as recycled product(s). Examples of
systems for processing dirt and/or debris mixtures are illustrated in
U.S. Pat. Nos. 5,234,608; 7,223,059; 7,264,190; and 7,296,676. The
complete disclosures of those patents are herein incorporated by
reference for all purposes.

[0003]Some debris mixtures may contain debris of different materials, such
as wood pieces and rock. Those debris mixtures need to be separated from
each other to have commercial value as recycled product(s) and/or for
further processing. Various equipment may be used that separate the
debris mixtures into separate piles, such as a pile primarily composed of
wood pieces and another pile primarily composed of rock.

SUMMARY OF THE DISCLOSURE

[0004]Some embodiments provide a vehicle for separating a mixed debris
stream. In some embodiments, the vehicle may include an elongate vehicle
frame; a separating structure mounted on the vehicle frame and configured
to contact the mixed debris stream with a fluid stream to separate the
mixed debris stream into at least a first debris stream and a second
debris stream, wherein the second debris stream includes at least some
material of a higher density than material from the first debris stream;
a first conveyor having a feed end portion positioned to receive the
first debris stream from the separating structure, and a discharge end
portion spaced from the feed end portion of the first conveyor; a second
conveyor having a feed end portion positioned to receive the second
debris stream from the separating structure, and a discharge end portion
spaced from the feed end portion of the second conveyor; and a fluid
collection structure configured to receive fluid from at least one of the
separating structure, the first conveyor, and the second conveyor, the
fluid collection structure including an upper tank, a lower tank, and one
or more conduits fluidly connecting the upper and lower tanks, wherein
the one or more conduits are free from a valve configured to regulate
flow from the upper tank toward the lower tank.

[0005]In some embodiments, the vehicle may include an elongate vehicle
frame; a separating structure mounted on the vehicle frame and configured
to contact the mixed debris stream with a fluid stream to separate the
mixed debris stream into at least a first debris stream and a second
debris stream, wherein the second debris stream includes at least some
material of a higher density than material from the first debris stream;
a first conveyor having a feed end portion positioned to receive the
first debris stream from the separating structure, and a discharge end
portion spaced from the feed end portion of the first conveyor; a second
conveyor having a feed end portion positioned to receive the second
debris stream from the separating structure, and a discharge end portion
spaced from the feed end portion of the second conveyor; and a fluid
collection structure configured to receive fluid from at least one of the
separating structure, the first conveyor, and the second conveyor, the
fluid collection structure including an internal wall defining an upper
tank and a lower tank, and one or more conduits fluidly connecting the
upper and lower tanks, wherein the one or more conduits are spaced from
the internal wall.

[0006]In some embodiments, the vehicle may include an elongate vehicle
frame; a separating structure mounted on the vehicle frame and configured
to contact the mixed debris stream with a fluid stream to separate the
mixed debris stream into at least a first debris stream and a second
debris stream, wherein the second debris stream includes at least some
material of a higher density than material from the first debris stream;
a first conveyor having a feed end portion positioned to receive the
first debris stream from the separating structure, and a discharge end
portion spaced from the feed end portion of the first conveyor; a second
conveyor having a feed end portion positioned to receive the second
debris stream from the separating structure, and a discharge end portion
spaced from the feed end portion of the second conveyor; and a fluid
collection structure configured to receive fluid from at least one of the
separating structure, the first conveyor, and the second conveyor, the
fluid collection structure including an internal wall defining an upper
tank and a lower tank, and one or more conduits fluidly connecting the
upper and lower tanks, wherein the one or more conduits are external the
upper and lower tanks and are free from a valve configured to regulate
flow between the upper and lower tanks.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is a side view of a material separator system mounted on a
vehicle frame.

[0008]FIG. 2 is a side view of the material separator system of FIG. 1
shown without a side of a tank and a portion of the vehicle frame to show
internal components of the material separator system.

[0009]FIG. 3 is a top view of the material separator system of FIG. 1.

[0010]FIG. 4 is a fragmented top view of the material separator system of
FIG. 1 shown without an upper conveyor to show a lower conveyor.

[0011]FIG. 5 is a sectional view of the lower conveyor taken along lines
5-5 in FIG. 4 of the material separator system of FIG. 1.

[0012]FIG. 6 is a fragmented top view of a conveyor belt of the upper
and/or lower conveyor of the material separator system of FIG. 1.

[0013]FIG. 7 is a side view of the material separator system of FIG. 1
shown without a side of a tank and a portion of the vehicle frame to show
an illustrative example of the flow of various streams when the material
separator system is in operation.

[0014]FIG. 8 is a fragmented top view of another example of a conveyor
belt of the upper and/or lower conveyor of the material separator system
of FIG. 1.

[0015]FIG. 9 is a partial view of the conveyor belt of FIG. 8.

[0016]FIG. 10 is a partial view of the material separator system of FIG. 1
shown without a side of a tank to show components of a separating
structure of the material separator system.

[0017]FIG. 11 is the partial view of FIG. 10 showing another illustrative
example of the flow of various streams when the material separator system
is in operation.

[0018]FIG. 12 is a partial isometric view of an internal wall of the
material separator system showing illustrative examples of conduits and a
flow directing assembly.

[0019]FIG. 13 is a top view of FIG. 12 showing another illustrative
example of a flow directing assembly.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0020]FIG. 1 depicts some embodiments of a material separator system 10.
The material separator system may be supported by a vehicle 210. Vehicle
210 may include an elongate vehicle frame 212 and transport wheels 214,
which may support the frame for movement over the ground. The vehicle
also may include one or more lifting legs 216, which may selectively
raise and/or lower material separator system 10 and/or vehicle frame 212.
For example, the lifting legs may allow a collection tank of the material
separator system to rest on the ground.

[0021]Although material separator system 10 is shown to be supported by a
particular vehicle, the material separator system may be supported by any
suitable structure configured to enable a user to relocate and/or move
the material separator system to one or more desired locations. For
example, material separator system 10 may be mounted on a vehicle with
transport tracks. Additionally, although vehicle 210 is shown to include
lifting legs 216, the vehicle may include any suitable structure
configured to allow a user to selectively raise and/or lower the material
separator system relative to the ground. For example, the vehicle may
additionally, or alternatively, include one or more airbag axles that may
support one or more of the transport wheels.

[0022]Material separator system 10 may include any suitable structure
configured to receive a mixed debris stream M and to at least partially
separate that stream into a plurality of debris streams P, such as a
first debris stream F and a second debris stream S, as shown in FIG. 7.
Material or debris in the debris streams may differ in density, weight,
size, length, width, thickness, and/or any suitable properties and/or
characteristics. For example, the second debris stream may include at
least some material of a higher density than material from the first
debris stream.

[0023]An illustrative example of a mixed debris stream M may include wood
pieces and rock. When the mixed debris stream includes those components,
then the material separator system may be configured to separate that
stream into at least a wood debris stream W and a rock debris stream R.
The wood debris stream may include at least a substantial portion of the
wood pieces from mixed debris stream M. Additionally, or alternatively,
the rock debris stream may include at least a substantial portion of the
rock from mixed debris stream M.

[0024]Although the mixed debris stream is discussed to include wood pieces
and rock, the mixed debris stream may alternatively, or additionally,
include other components such as fibrous material, dirt, gravel, etc.
Additionally, although material separator system 10 is discussed to
separate mixed debris stream M into wood debris stream W and rock debris
stream R, the material separator system may additionally, or
alternatively, be configured to separate the mixed debris stream into
other suitable streams.

[0025]Moreover, although material separator system 10 is discussed to
separate mixed debris stream M into two debris streams, the material
separator system may be configured to separate the mixed debris stream
into three or more streams. Furthermore, although material separator
system 10 is discussed to separate mixed debris stream M into plurality
of streams P, the material separator system may separate only one or more
portions of the mixed debris stream into the plurality of streams.
Additionally, although material separator system 10 is discussed to
receive a mixed debris stream, the material separator system may receive
two or more debris streams, each of those streams may be mixed and/or at
least substantially include one or more types of debris.

[0026]An illustrative example of material separator system 10 may include
a feed structure 12, a separating structure 14, a fluid collection
structure 16, and a conveying structure 18, as shown in FIGS. 1-2. Feed
structure 12 may include any suitable structure configured to feed a
mixed debris stream to a mixing tank of the separating structure. For
example, feed structure 12 may include a feed hopper 20 and a feed
conveyor 22, as shown in FIG. 1.

[0027]The feed hopper may be configured to receive mixed debris stream M
from any suitable source(s), such as one or more material processing
systems. Feed conveyor 22 may be configured to receive mixed debris
stream M from the feed hopper and to transport the mixed debris stream to
separating structure 14. Although feed structure 12 is shown to include
feed hopper 20 and feed conveyor 22, the feed structure may include any
suitable structure configured to feed mixed debris stream M to the
separating structure.

[0028]Separating structure 14 may be mounted on, supported by, or
operatively connected to the vehicle frame. The separating structure may
include any suitable structure configured to separate mixed debris stream
M into at least first debris stream F and second debris stream S. For
example, separating structure 14 may include a mixing area or mixing tank
24, a fluid ejection assembly 26, and a conveying assembly 28, as shown
in FIG. 2. The mixing tank and the fluid ejection assembly also may be
referred to as a separating assembly 29.

[0029]Mixing tank 24 may include any suitable structure configured to
contact mixed debris stream M with one or more fluid streams L from fluid
ejection assembly 26 to separate the mixed debris stream to at least
first debris stream F and second debris stream S. For example, mixing
tank 24 may include one or more walls 30 and one or more skirts 32, which
may at least partially contain the mixed debris stream and the fluid
streams. In some embodiments, mixing tank 24 may be an area within and/or
be in fluid communication with an upper portion of a collection tank of
the fluid collection structure.

[0030]In some embodiments, where the mixed debris stream M is contacted by
the one or more fluid streams, at least some of the plurality of streams
may include fluid from the fluid streams. For example, at least one of
the first debris stream and the second debris stream may include at least
some fluid from the fluid stream. Alternatively, the wood debris stream
may include at least some fluid from the fluid stream and/or the rock
debris stream may include at least some fluid from the fluid stream.

[0031]Fluid ejection assembly 26 may include any suitable structure
configured to receive fluid from fluid collection structure 16 and to
eject one or more fluid streams L to the mixing tank. The fluid streams
may include any suitable fluid(s). For example, the fluid streams may at
least substantially include water. When the fluid streams at least
substantially include water, fluid ejection assembly 26 may be referred
to as a water ejection assembly. The fluid ejection assembly may include
a fluid pump 34 and a fluid pipe 36, as shown in FIG. 2. The fluid pump
may move fluid from the fluid collection structure to the fluid pipe.
Fluid pipe 36 may direct fluid from the fluid pump to eject one or more
fluid streams L to mixing tank 24.

[0032]Although fluid ejection assembly 26 is shown to include a single
pump and a single pipe, the fluid ejection assembly may include two or
more pumps and/or two or more pipes. Additionally, although fluid
ejection assembly 26 is shown to receive fluid from the fluid collection
structure, the fluid ejection assembly may alternatively, or
additionally, receive fluid from any suitable source(s). Moreover,
although fluid ejection assembly 26 is shown to include fluid pump 34 and
fluid pipe 36, the fluid ejection assembly may include any suitable
structure to receive fluid from fluid collection structure 16 and to
eject one or more fluid streams L to the mixing tank.

[0033]As shown in FIGS. 10-11, the fluid ejection assembly may include a
fluid channeler 106 configured to selectively direct the one or more
fluid streams entering mixing area 24 among a plurality of ejection
angles relative to a suitable reference plane, such as a horizontal plane
H. For example, fluid channeler 106 may include a flap 110 and a control
mechanism 112. The flap may be mounted and/or movably connected on any
suitable portion of the fluid ejection assembly, such as an end portion
108 of fluid pipe 36. For example, the flap may be pivotally connected to
the end portion of the fluid pipe and may be configured to be selectively
pivoted by the control mechanism to selectively direct the one or more
fluid streams among a plurality of ejections angles, such as ejection
angles A1 and A2.

[0034]In some embodiments, the one or more fluid streams may contact the
mixed debris stream at a contact region C spaced from the feed end
portion of the first conveyor. The fluid channeler may then be configured
to selectively direct the one or more fluid streams to move the contact
region among a plurality of locations relative to feed end portion 42 of
first conveyor 38. For example, the fluid channeler may direct fluid
stream L1 to contact the mixed debris stream at contact region C at a
first location C1 (which may be adjacent to feed end portion 42 and/or at
a first distance D1 from feed end portion 42), and/or direct fluid stream
L2 to contact the mixed debris stream at contact region C at a second
location C2 (which may be spaced from feed end portion 42 relative to the
first location and/or at a second distance D2 from feed end portion 42.
First distance D1 may be less than, equal to, or greater than second
distance D2.

[0035]An ejection angle or a contact region location may be selected
based, at least in part, on one or more properties of the fluid stream
and/or mixed debris stream. For example, the contact region location
selected may be based, at least in part, on a difference between an
average density of material intended to be part of the first debris
stream, and an average density of material intended to be part of the
second debris stream. Based on that difference a larger (or smaller)
ejection angle and/or contact region location farther from (or closer to)
the feed end portion of the first conveyor may be required to ensure
sufficient or adequate separation of material from the mixed debris
stream.

[0036]Although fluid channeler 106 is shown to include flap 110 and
control mechanism 112, the fluid channeler may include any suitable
structure configured to selectively direct the one or more fluid streams
entering the mixing area among a plurality of ejection angles and/or to
selectively direct the one or more fluid streams to move the contact
region among a plurality of locations relative to the feed end portion of
the first conveyor. Additionally, although the plurality of ejection
angles include ejection angle A1, which is shown to be zero or parallel
to the horizontal plane, and ejection angle A2, which is shown to be
positive or above the horizontal plane, the plurality of ejection angles
may alternatively, or additionally, include any suitable angles,
including ejection angles that are negative or below the horizontal
plane.

[0037]Moreover, although separating structure 14 is shown to include fluid
channeler 106, feed structure 12 may alternatively, or additionally,
include a fluid channeler. For example, the fluid channeler of the feed
structure may be configured to selectively direct the mixed debris stream
entering the mixing area among a plurality of ejection angles relative to
any suitable reference plane and/or to move a contact region among a
plurality of locations.

[0038]Conveying assembly 28 may include any suitable structure configured
to transport at least the first and second debris streams away from the
mixing tank. For example, the conveying assembly may include a first
conveyor 38 and a second conveyor 40, as shown in FIGS. 2-4. The first
conveyor may include a feed end portion 42 and a discharge end portion
44, and may be configured to transport the first debris stream (such as
the wood debris stream) from the feed end portion to the discharge end
portion. Feed end portion 42 may be disposed within or adjacent the
mixing tank to receive the first debris stream and/or disposed within or
adjacent an upper tank or upper portion of a collection tank of the fluid
collection structure (discussed further below), and discharge end portion
44 may be spaced from the feed end portion, as shown in FIGS. 2-3. In
some embodiments where the first debris stream includes the wood debris
stream, the first conveyor may be referred to as a wood conveyor.
Additionally, first conveyor 38 may include a first conveyor belt 46 and
first conveyor rollers 48, as shown in FIGS. 2-3. The first conveyor
rollers may be configured to move the first conveyor belt.

[0039]Second conveyor 40 may include a feed end portion 50 and a discharge
end portion 52, and may be configured to transport the second debris
stream (such as the rock debris stream) from feed end portion 50 to
discharge end portion 52. Feed end portion 50 may be disposed within or
adjacent the mixing tank and/or disposed within or adjacent an upper tank
or upper portion of a collection tank of the fluid collection structure
(discussed further below) to receive the second debris stream, and
discharge end portion 52 may be spaced from feed end portion 50, as shown
in FIGS. 2 and 4.

[0040]In some embodiments, where the second debris stream includes the
rock debris stream, the second conveyor may be referred to as a rock
conveyor. Additionally, second conveyor 40 may include a second conveyor
belt 54 and second conveyor rollers 56, as shown in FIGS. 2 and 4. The
second conveyor rollers may be configured to move the second conveyor
belt.

[0041]First conveyor belt 46 and second conveyor belt 54 may include any
suitable type(s) of belt and/or be made of any suitable material(s)
configured to move one or more debris streams from the feed end portion
to the discharge end portion of the belt(s), and/or to drain at least
some fluid from at least one of the first debris stream and the second
debris stream, such as to or toward the fluid collection structure (e.g.,
an upper tank or upper portion of a collection tank). For example, the
first conveyor belt and/or the second conveyor belt may include a mesh
conveyor belt.

[0042]"Mesh conveyor belt," as used herein, refers to a conveyor belt that
includes an open structure made of a plurality of members with at least
some of the members being overlapped and/or overlaid in a regular and/or
irregular pattern. The mesh conveyor belt may include one or more layers
of material(s), each of which includes at least a portion with an open
structure made of a plurality of members with at least some of the
members being overlapped and/or overlaid in a regular and/or irregular
pattern. The mesh conveyor belt may be made of any suitable material(s),
such as one or more plastic materials, one or more wire materials, and/or
one or more rubber materials.

[0043]Alternatively, or additionally, the first and/or second conveyor
belts may include a non-mesh conveyor belt. "Non-mesh conveyor belt," as
used herein, refers to a conveyor belt that is not a mesh conveyor belt,
as defined above. The non-mesh conveyor belt may include one or more
layers with each layer made of any suitable material(s). When the
non-mesh conveyor belt includes "n" number of layers, up to "n-1" of
those layers may at least partially include an open structure made of a
plurality of members with at least some of the members being overlapped
and/or overlaid in a regular and/or irregular pattern. Additionally, the
non-mesh conveyor belt may include any suitable top or top layer, such as
a flat top, friction top, rib top, etc.

[0044]The non-mesh conveyor belt may be made of any suitable material(s).
For example, the non-mesh conveyor belt may at least substantially be
made of rubber and/or rubber material(s). The non-mesh conveyor belt may
include one layer (or ply) or multiple layers (or plies). Additionally,
the non-mesh conveyor belt, which is generally indicated at 55 in FIG. 6,
may include a plurality of perforations and/or holes 58, and a plurality
of retaining members 60. The plurality of perforations and/or holes may
be configured to drain at least some fluid from at least one of the first
debris stream and the second debris stream, such as to or toward the
fluid collection structure. The holes may be any suitable size, such as
3/8 inches in diameter, and/or may be spaced any suitable distance, such
as 3/4 inches.

[0045]Retaining members 60 may include any suitable structure configured
to prevent at least some material of the debris stream from moving
towards feed end portion 50. For example, the retaining members may
include cleats 62, as shown in FIG. 6. The cleats may be any suitable
dimensions and/or any suitable shape(s). For example, at least some of
the cleats may be elongate. Alternatively, or additionally, at least some
of the cleats may be chevron-shaped and/or any other suitable shapes.

[0046]The holes and/or retaining members may be positioned on the belt in
any suitable manner. For example, the holes may be distributed across at
least a substantial portion of the second conveyor belt, such as on one
or more perforated portions 61 of the second conveyor belt.
Alternatively, or additionally, at least some of the holes may be
arranged in plural rows and at least some of the retaining members may be
disposed between the plural rows on one or more solid portions 63 of the
second conveyor belt.

[0047]Although holes 58 are shown to be distributed across a substantial
portion of the non-mesh conveyor belt, the holes may be distributed
across any suitable portion(s) of the non-mesh conveyor belt.
Additionally, although the retaining members are shown to be positioned
on solid portions 63 of the non-mesh conveyor belt, the retaining members
may alternatively, or additionally, be disposed or positioned on any
suitable location(s). For example, at least some of the retaining members
may be positioned within the perforated portions of the non-mesh conveyor
belt. Moreover, although holes 58 are shown to be arranged in plural
rows, the holes may alternatively, or additionally, be arranged in any
suitable way(s), such as staggered, regular, and/or irregular patterns.

[0048]Another example of a non-mesh conveyor belt is shown in FIGS. 8-9
and is generally indicated at 155. Non-mesh conveyor belt 155 may be made
of any suitable material(s). For example, the non-mesh conveyor belt may
at least substantially be made of rubber and/or rubber material(s). The
non-mesh conveyor belt may include one layer (or ply) or multiple layers
(or plies). Additionally, non-mesh conveyor belt 155 may include a
plurality of perforations and/or holes 158. The plurality of perforations
and/or holes may be configured to drain at least some fluid from at least
one of the first debris stream and the second debris stream, such as
toward the fluid collection structure. The holes may be any suitable
size, such as 5/16 inches in diameter, and/or may be spaced any suitable
distance, such as 5/16 inches.

[0049]Holes 158 may be positioned on the belt in any suitable manner. For
example, the holes may be distributed across at least a substantial
portion of the non-mesh conveyor belt, such as on one or more perforated
portions 161 of the non-mesh conveyor belt. Alternatively, or
additionally, at least some of holes 158 may be grouped in plural arrays
of holes, and at least some of the array of holes may include plural rows
of holes. The plural rows of holes may have regular, staggered, and/or
irregular patterns. For example, the staggered plural rows of holes are
shown in FIGS. 8-9. Additionally, or alternatively, at least some of the
array of holes may be spaced from the other array of holes via one or
more solid portions 162 of the non-mesh conveyor belt.

[0050]The non-mesh conveyor belt may include any suitable number of
perforated portions and solid portions. For example, the non-mesh
conveyor belt may include one or more horizontal solid portions 164, and
one or more vertical portions 165, as shown in FIGS. 8-9. The perforated
portions and the solid portions may have any suitable dimensions. For
example, for a belt with a 36'' width (measured perpendicular to the
direction of travel for the belt), the perforated portions may have a
width of about 7 inches (such as 7 3/16 inches), and the solid portions
may have a width of about 0.5 inches (such as 5/16 inches between
perforated portions) to about 3 inches (such as 3 3/16 inches at the
perimeter of the belt). Additionally, or alternatively, the horizontal
solid portion may have a length (measured in the direction of travel for
the belt) of about 6 inches.

[0051]Although a particular arrangement for the perforated and solid
portions is shown, those portions may be arranged in any suitable way(s).
Additionally, although particular dimensions are given for the perforated
and solid portions, those portions may have any suitable dimensions.
Moreover, although holes 158 are shown to be distributed across a
substantial portion of the non-mesh conveyor belt, the holes may be
distributed across any suitable portion(s) of that belt. Furthermore,
although holes 158 are shown to be arranged in plural staggered rows, the
holes may alternatively, or additionally, be arranged in any suitable
way(s), such as regular and/or irregular patterns.

[0052]First conveyor belt 46 and second conveyor belt 54 may include any
of the conveyor belts discussed herein and/or any other suitable conveyor
belt(s). For example, first conveyor belt 46 may include non-mesh
conveyor belt 155, and second conveyor belt 54 may include non-mesh
conveyor belt 55. Alternatively, first conveyor belt 46 may include a
plastic mesh belt, and second conveyor belt 54 may include non-mesh
conveyor belt 55.

[0053]Although first conveyor belt 46 is discussed to include non-mesh
conveyor belt 155 or a plastic mesh belt, the first conveyor belt may
include any suitable type of belt made of any suitable material(s), such
as a wire mesh belt and/or non-mesh conveyor belt 55. Additionally,
although second conveyor belt 54 is shown to include non-mesh conveyor
belt 55, the second conveyor belt may be any suitable type(s) of belt
and/or be made of any suitable material(s). For example, second conveyor
belt 54 may alternatively be a mesh conveyor belt, and/or may be made of
plastic, wire, and/or any suitable material(s). Moreover, although
separating structure 14 is shown to include mixing tank 24, fluid
ejection assembly 26, and conveying assembly 28, the separating structure
may include any suitable components configured to separate mixed debris
stream M into the plurality of debris streams.

[0054]Fluid collection structure 16 may include any suitable structure
configured to collect fluid from separating structure 14. When fluid
collection structure 16 collects fluid(s) that at least substantially
includes water, then the fluid collection structure also may be referred
to as a water collection structure. An illustrative example of fluid
collection structure 16 may include a collection tank 64, which may
include a plurality of tank walls 65 defining an interior 66, an internal
wall 68 positioned within that interior, and one or more conduits 70, as
shown in FIG. 2. Interior 66 is sized to receive and collect fluid from
separating structure 14. The internal wall may at least partially divide
interior 66 of the collection tank between an upper portion 74 and a
lower portion 76, as shown in FIG. 2. The upper portion and the lower
portion also may be referred to as an upper tank and a lower tank,
respectively. Upper portion 74 may be configured to receive fluid from
separating structure 14.

[0055]Although internal wall 68 is shown to divide interior 66 of the
collection tank at a particular angle, the internal wall may divide the
interior of the collection tank at any suitable angle(s) and/or any
suitable location(s). For example, the internal wall may be horizontal to
increase a volume of the upper portion relative to the lower portion.
Additionally, although fluid collection structure 16 is shown to include
a single collection tank with an internal wall, the fluid collection
structure may include separate or discrete tanks that may be in fluid
communication with each other, such as a first or upper tank and a second
or lower tank.

[0056]Conduits 70 may include any suitable structure configured to fluidly
connect upper portion 74 and lower portion 76. The collection tank may
have any suitable number of conduits 70. In some embodiments, one or more
of the conduits may be free from a valve and/or other structure
configured to regulate flow from the upper portion toward the lower
portion. For example, conduits 70 may include one or more passages 82
extending between the upper and lower portions.

[0057]Passages 82 may be located at any suitable locations. For example,
the passages may be located on and/or adjacent to internal wall 68, as
shown in FIG. 13. Alternatively, or additionally, the passages may be
spaced from the internal wall, external the upper and/or lower portions,
and/or external the tanks walls of the collection tank. Any suitable
number of passages 82 may fluidly connect the upper and lower portions.
For example, the collection tank may include two passages as shown in
FIG. 13. Alternatively, the collection tank may include one, three, four
or more passages.

[0058]The collection tank may additionally, or alternatively, include at
least one flow directing assembly 83, which may include any suitable
structure configured to direct fluid from the upper portion toward one or
more of the conduits, such as one or more of the passages. For example,
the flow directing assembly may include one or more sloped walls 84 that
may be sloped toward one or more conduits 70. The sloped walls may be
located at any suitable location(s), such as adjacent one or more of the
conduits. In some embodiments, the sloped walls or the flow directing
assembly may be movably connected, such as to the internal wall, to allow
a user to selectively block one or more of the conduits.

[0059]The flow directing assembly may additionally, or alternatively,
include a bubbler 85, as shown in FIG. 14. The bubbler may include any
suitable structure configured to inject fluid into the upper portion,
such as through a plurality of apertures 86 on one or more of the sloped
walls. The fluid may be from the lower portion, an external source,
and/or any other suitable sources. The bubbler may include any suitable
mechanism or device, such as a pump (not shown), to inject the fluid into
the upper portion.

[0060]Although flow directing assembly 83 is shown to include two sloped
walls 84, the flow directing assembly may include any suitable number of
sloped walls, such as one, three, four or more. Additionally, although
sloped walls 84 are shown to be between the passages, the sloped walls
may alternatively be between one or more passages. For example, a central
passage may be used with two or more sloped walls between that passage.

[0061]Conduits 70 may alternatively, or additionally include one or more
weirs 87, which may include any suitable structure configured to allow
fluid from the upper portion to flow toward the lower portion when a
fluid level in the upper portion is beyond a predetermined level. The
weirs may be located in any suitable portion(s) of the collection tank,
such as spaced from the internal wall, external the upper and/or lower
portions, and/or external the tank walls of the collection tank.
Collection tank 64 may include any suitable number of weirs 87, such as
one, two, three or more weirs. For example, collection tank 64 may
include two weirs, one on each side tank wall of the collection tank.

[0062]Although weirs 87 are shown to be positioned toward a rear portion
of the tank, the weirs may additionally, or alternatively, be positioned
on any suitable portions of the tank, include a front portion of the
tank. Additionally, although collection tank 64 is shown to include
passages 82 and weirs 87 to fluidly connect the upper and lower portions,
the collection tank may alternatively, or additionally, include any
suitable type(s) of conduits.

[0063]For example, the conduit may include a drain valve (such as a
flapper valve and/or another suitable valve. The conduit may be
positioned at any suitable location. For example, the conduit may be
located on internal wall 68 and/or a bottom of the upper portion (or
upper tank).

[0064]Alternatively, or additionally, the conduit may include a bypass
pipe and a bypass valve. The conduit may be positioned at any suitable
location. For example, the conduit may be located external the tank walls
of the collection tank. In some embodiments, the conduit may be
configured to drain one or more streams of fibrous material B from the
upper portion to the lower portion of the collection tank. The collection
tank may have two or more conduits located external the tank walls of the
tank as an alternative to, or in addition to, one or more conduits
located internal the tank.

[0065]Fluid collection structure 16 also may include a removal assembly
88, which may include any suitable structure configured to remove one or
more materials (such as fibrous material stream(s) B, stream(s) of silt
materials, stream(s) of sand materials, and/or other streams of suitable
materials) from the fluid in the collection tank. For example, removal
assembly 88 may include a drag member 90 (such as a drag chain) and
rollers 92, as shown in FIG. 2. The rollers may move drag member 90 such
that at least some of the materials may be collected and/or moved by the
drag member from the fluid in the collection tank. Those materials may be
discharged to a discharge end portion 94 of collection tank 64 to one or
more conveyors of conveying structure 18.

[0066]Although removal assembly 88 is shown to include drag member 90 and
roller 92, the removal assembly may include any suitable structure
configured to remove one or more materials from the fluid in the
collection tank. Additionally, although fluid collection structure 16 is
shown to include collection tank 64 and removal assembly 88, the fluid
collection structure may include any suitable structure configured to
collect fluid from separating structure 14.

[0067]Conveying structure 18 may include any suitable structure configured
to transport debris streams and/or materials from the separating
structure and/or fluid collection structure to desired location(s), such
as desired pile(s) and/or structure(s). For example, conveying structure
18 may include a third conveyor 96, a fourth conveyor 98, and a fifth
conveyor 100. The third conveyor may be configured to transport material,
such as fibrous material stream(s) B (and/or stream(s) of silt and/or
sand materials) from the collection tank, from discharge end portion 94
to the desired location(s). Fourth conveyor 98 may be configured to
transport material, such as the rock debris stream, from the second
conveyor to the desired location(s), while fifth conveyor 100 may be
configured to transport material, such as the wood debris stream, from
the first conveyor to the desired location(s).

[0068]Although third conveyor 96, fourth conveyor 98, and fifth conveyor
100 are shown to have specific orientations that extend away from the
vehicle frame, one or more of those conveyors may include any suitable
orientations. In some embodiments, one or more of those conveyors may be
selectively adjusted to the desired orientation(s). For example, one or
more conveyors may be adjustable conveyors as described in U.S. patent
application Ser. Nos. 10/971,355 and 11/053,729, the complete disclosures
of which have been incorporated by reference for all purposes.
Additionally, although conveying structure 18 is shown to include the
third, fourth, and fifth conveyors, the conveying structure may include
any suitable number of conveyors and/or any suitable structure configured
to transport material from the separating structure and/or fluid
collection structure to the desired location(s).

[0069]Material separator system 10 may include at least one power supply
102, which may include any suitable structure configured to at least
partially provide power to the feed structure, separating structure,
fluid collection structure, and/or conveying structure. For example,
power supply 102 may include at least one diesel engine 104. Although
power supply 102 is shown to include a diesel engine, the power supply
may include any suitable power supply configured to at least partially
provide power to the feed structure, separating structure, fluid
collection structure, and/or conveying structure. For example, the power
supply may alternatively, or additionally, include one or more batteries,
power cells, gasoline engines, hydraulic systems. Alternatively, or
additionally, the power supply may include structure to connect the
material separator system to one or more power utility grids.

[0070]An illustrative example of the flow of various streams when the
material separator system is in operation is shown in FIG. 7. In
operation, material separator system 10 may be lowered such that
collection tank 64 rests on a ground surface and/or on one or more
leveling members. Fluids may be introduced to the mixing tank and/or
collection tank to establish operating water levels in the upper and
lower portions of the collection. At least one mixed debris stream M may
be fed to the feed hopper. Those streams may be moved to the mixing tank
via the feed conveyor. In the mixing tank, the mixed debris stream may be
contacted with the fluid stream from the fluid ejection assembly.

[0071]The fluid stream may push or move material of lower density and/or
weight towards the feed end portion of the first conveyor. Additionally,
material of higher buoyancy may float and/or move upward the mixing tank
to the feed end portion of the first conveyor. The material and/or fluid
moved from the feed end portion towards the discharge end portion of the
first conveyor may be characterized as first debris stream F or wood
debris stream W. From that discharge end portion, the first debris stream
may be received by the fifth conveyor, which may move first debris stream
F from the discharge end portion of the first conveyor to desired
location(s).

[0072]In contrast, material of higher density and/or weight (and/or lower
buoyancy) may sink or fall down the mixing tank to the feed end portion
of the second conveyor. The material and/or fluid moved from the feed end
portion towards the discharge end portion of the second conveyor may be
characterized as second debris stream S or rock debris stream R. From
that discharge end portion, the second debris stream may be received by
the fourth conveyor, which may move second debris stream S to desired
location(s).

[0073]As the first conveyor moves material from its feed end portion
towards its discharge end portion, fluid may be drained or removed from
the first debris stream to the second conveyor. Fluid from the first
debris stream may drain through the open structure of the mesh conveyor
belt of the first conveyor. Similarly, as the second conveyor moves
material from its feed end portion towards its discharge end portion,
fluid (which may include fluid from the first debris stream) may be
drained or removed from the second debris stream to the upper portion of
the collection tank. Fluid from the second debris stream may drain
through the holes of the non-mesh conveyor belt of the second conveyor.

[0074]Fluid collected in the upper portion of the collection tank may
drain to the lower portion of that tank via the first and/or second
conduits. Fibrous material, silt material, and/or sand material in the
fluid of the upper portion may drain via the second conduit and/or the
first conduit to the lower portion in one or more fibrous material
streams B. The fluid may then be moved from the lower portion to the
mixing tank via the pump and the pipe.

[0075]The fibrous material stream(s) B (and/or stream(s) of silt and/or
sand materials) may be moved to the discharge end portion of the
collection tank via the drag member and the rollers. From the discharge
end portion, fibrous material streams B may be received by the third
conveyor and may be moved to desired location(s). However, the steps
discussed above may be performed in different sequences and/or in
different combinations, not all steps being required for all embodiments
of the material separator system.

[0076]Although the material separator system and features of the material
separator system have been shown and described with reference to the
foregoing operational principles and preferred embodiments, those skilled
in the art will find apparent that various changes in form and detail may
be made without departing from the spirit and scope of the claims. The
present disclosure is intended to embrace all such alternatives,
modifications, and variances that fall within the scope of the appended
claims.